Delphi Helps Vehicles Lose Weight, Save Space

With the addition of more electronically driven features, and increased standard offerings of optional features, E/E architecture has taken on a prominent role, Steve Duca, director, global engineering and operations, Delphi Packard E/EA, said. Not only is it important for the power and signal distribution system to ensure these features function reliably, it also represents an important challenge to continually minimize complexity and reduce mass. This system can be one of the most complex in the vehicle, hence our focus on space and weight savings.



Smaller is Better When it Comes to Cable



The harsh environment and physical abuse that automotive primary wiring must withstand has previously limited the introduction of wires smaller than 0.35 mm2 (22 gauge) into vehicle wire harnesses. Delphi has developed ways to slim its high-performance cables to a thin 0.13 mm2 (26 gauge). These small-gauge cables are created with advanced materials in both the cable core and the insulation -- technology that was a 2010 Automotive News PACE (Premier Automotive Suppliers' Contribution to Excellence) Award finalist. Delphi’s reduced gauge cable also provides improved tensile strength along with increased pinch and abrasion protection.



Additionally, advances in manufacturing technology such as automated assembly processes continue to enable the trend toward miniaturization to reduce the size and weight of products. Assembly of small-gauge wiring through the use of state-of-the-art manufacturing processes will be required by factories of the future.



Aluminum Cable - Lightweight Performer



A lightweight alternative that enhances performance, Delphi Aluminum Cable offers up to a 48 percent weight reduction over traditional copper core cable. Since approximately half a pound (227 g) of aluminum can replace one pound (454 g) of copper, about four pounds (1.8 kg) of weight can be trimmed from a typical vehicle by swapping the two materials in a wiring harness.



Delphi Aluminum Cable is an excellent alternative for primary cable applications, Duca said. With our unique aluminum core alloy, cable manufacturing process, and state-of-the-art crimping technology, Delphi Aluminum Cable is well suited for use in passenger compartments and other locations as it also yields higher flex-fatigue life.



Aluminum prices have historically been more stable than copper, he added, so Delphi Aluminum Cable can also help OEMs reduce their susceptibility to commodity market fluctuations.



Miniaturized Connections



Delphi’s 0.50 Connection Systems are high-density connections smaller in size than typical .64 systems. They also offer up to a 60 percent reduction in mass and up to a 50 percent reduction in packaging volume. Validated to USCAR-2, these connection systems crimp to cable as small as 0.05mm² to enable the next generation of mass reduction and miniaturization.



Space-Saving Electrical Centers



Delphi’s first-to-market electrical center solution utilizing micro-fuses helps improve packaging size by as much as 30 percent. The micro-fuses are 35 percent smaller than traditional mini-fuses and allow more circuits to be placed in a given area on the printed circuit board, which means the electrical center can accommodate more content and functionality.